Strain relief antenna wiring connector in an electronic device

ABSTRACT

A method for manufacturing an electronic device including configuring one or more circuit boards with a plurality of antennas connected to at least one circuit board having wire securing slots. The electronic device having vertical orientation and an outer casing including a case bottom piece, a case top front piece, and a case top back piece. Features include providing staging slots in the case top back piece holding the board at an angle with respect to the interior surface of the case top back piece to permit connections to the circuit board which includes connecting antenna wires to connectors on the circuit board having antenna wires secured in wire securing slots prior to connecting to antenna connectors. The circuit board attached to only one side wall of one of the case front top piece or the case top back piece.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser.No. 62/150,062, filed Apr. 20, 2015, which is incorporated by referenceherein in its entirety.

FIELD

The present principles relate generally to electronics and, moreparticularly, to an electronic apparatus and antenna mountingarrangement within an electronic device.

BACKGROUND

Electronic devices such as set-top boxes are typically assembledapparatuses having a plurality of walls and other components. Theseother components can include printed circuit boards, heat sinks or heatspreader, wires, hard drives, smart card assemblies, and antennas. Theplurality of walls and components make the assembly of these devicesquite challenging in high volume manufacturing environments. As such,there is a need to insure that the components are staged, mounted, andinstalled in a manner that is fast and safe for the components. Further,there is a need to insure that the components are inspectable anddesigned in a manner that makes their installation as reversible aspossible for rework in the factory or in the field.

As such, some devices such as the vertically oriented set top boxdisclosed in International Application No. PCT/US15/17791 filed on Feb.26, 2015 incorporate screwless attachment concepts to assemble thehousings of the devices in such a way that the access to the devices inthe field can be performed in a safe efficient manner by an authorizedperson without the need to undue screws. Such designs as in the abovementioned application make gaining access to the interior components ofthese devices more convenient and reduce excessive handling.

The casings of the vertically oriented set top boxes and gateway devicesare relatively tall. The bases are generally narrow. With such ageometry, these designs present more challenges than the horizontallyoriented set top boxes for screwless housing assembling. The reason isit is difficult to include a locking mechanism in these tall boxes thatcan extend from the top side to the bottom side of the boxes and yetstill be able to house the plurality of necessary components which caninclude a plurality of antennas without interfering with the lockingmechanism.

The need for a plurality of antennas in these vertically oriented settop boxes or gateway devices particularly presents a challenge. Theproblem is that in some designs up to 7 antennas are required, whichmeans that additional wires must be used to connect the antennas to acircuit board and additional fixtures or antenna supports must beinstalled in the devices to support the antennas. Further, the antennasnot only involve extra handling of the work product in the factory thatplace other components at risk and drive up manufacturing cost, but alsothese antennas have a propensity for electrostatic discharge in use. Assuch, designers must ensure that the antennas are adequately shielded inthese devices which tend to be quite crowded. Thus, the need exists foran antenna mounting system that is commensurate with the screwlessattachment concepts and yet do not pose the risk of electrostaticdischarge to and from the antennas.

These and other drawbacks and disadvantages presented by verticallyoriented electronic devices are addressed by the present principles,which are directed to a vertical electronic apparatus and associatedprinted circuits. However, it can be understood by those skilled in theart that the principles can be taken advantage of in horizontallyoriented devices as well.

SUMMARY

According to the present principles, a method is provided formanufacturing an electronic device that includes configuring one or moreprinted circuit boards with a plurality of antennas 602 connected to atleast one printed circuit board having wire securing slots 540. Theelectronic device can have a vertical orientation and an outer casingthat includes a case bottom piece, a case top front piece and a case topback piece. The features can include providing staging slots 230 in thecase top back piece for holding the board 501 at an angle with respectto the interior surface of the case top back piece to permit connectionsto the printed circuit board which can include connecting antenna wires604 to antenna connectors 606 on the printed circuit board in which theantenna wires 604 secured in the wire securing slots 540 prior toconnecting to the antenna connectors. The printed circuit board can beattached to only one side wall of one of the case front top piece or thecase top back piece.

According to the present principles, a method is provided forconstructing a sub-assembly for incorporating into a plurality ofdifferent set top boxes and gateway devices that includes forming aplurality of slots along an edge of a printed circuit board, arranging aplurality of electrical connectors on a side of the printed circuitboard adjacent to the edge, providing a plurality of antennas withrespective lead wires, securing the respective lead wires in respectiveones of the slots, and operatively connecting the lead wires torespective ones of the electrical connectors. The method can includesupporting the antennas from a position above the printed circuit boardand can include positioning the electrical connectors laterally withrespect to the slots, in a direction parallel to the edge of the printedcircuit board. The slots can be configured to be substantially T-shaped,substantially J-shaped. substantially L-shaped, or substantiallycheck-mark (✓) shaped.

According to the present principles, an electronic device 200 such as aset top box or gateway device is provided that comprises a printedcircuit board 501 having wire securing slots 540 along an edge of theprinted circuit board and electrical connectors 606 on a side 504 of theprinted circuit board adjacent to the edge and electronic components 602having wires 604 extending therefrom in which the wires are each securedin one of the wire securing slots and connected to one of the electricalconnectors. The wire securing slots can be substantially a J-shape,substantially a check design (✓) shape, substantially a T-shape, orsubstantially an L- shape. The electronic components can be antennas andthe electrical connectors can each be positioned laterally with respectto the wire securing slots in a direction parallel to the edge of theprinted circuit board. The electronic device can further comprise anantenna bracket 601 that supports the antennas. The electronic devicecan further comprise a casing that is a vertically oriented structure inwhich the height of the casing is greater than horizontal widths of eachof its sides and all horizontal depths of the casing. The antennabracket can be positioned above the printed circuit board. The printedcircuit board can be positioned vertically and the edge can be an upperedge of the printed circuit board. The antenna bracket can be apolygonal structure having at least two sides 603 that support theantennas. The printed circuit board can be secured to a rear wall 206 ofthe casing and can be parallel to the rear wall. The antenna bracket canalso be secured to the rear wall (206) of the casing. The wires of theantennas can be routed to one of the sides of the antenna bracket anddown to the wire securing slots. The rear wall can have at least onestaging slot (230) in the at least one staging slot is configured totemporarily support the printed circuit board during assembly of theelectronic device. The staging slot can be one elongated slot.

BRIEF DESCRIPTION OF THE DRAWINGS

The present principles can be better understood in accordance with thefollowing exemplary figures, in which:

FIG. 1 is a perspective view of a vertically oriented electronic device200 to which the current principles are applied;

FIG. 2 is a disassembled perspective view of the vertically orientedelectronic device 200;

FIG. 3 is a perspective view of a retention clip 214;

FIG. 4 is a perspective view of the casing that shows how the pieces ofthe casing are assembled;

FIG. 5 is a perspective view of the casing that shows a case backretaining element;

FIG. 6 is a perspective view of the casing that shows a cross-section ofan interlock;

FIG. 7 is a perspective view of the casing that shows an opening on thecase front;

FIG. 8 is a perspective view of the retaining elements of the verticallyoriented electronic device 200;

FIG. 9 is another perspective view of the retaining elements of thevertically oriented electronic device 200;

FIG. 10 is a disassembled perspective view of the vertically orientedelectronic device 200;

FIG. 11 is a bottom perspective view of the vertically orientedelectronic device 200 and the retention clips 214;

FIGS. 12-14 are various views of the retention clips 214;

FIG. 15 is a perspective view of the case bottom piece 213;

FIGS. 16 and 17 are perspective views showing how the bottom piece 213engages the case top front piece and the case top back piece;

FIG. 18 is a bottom perspective view of the vertically orientedelectronic device 200;

FIG. 19 is a view of the release fixture 300;

FIG. 20 is a flow diagram showing an exemplary method 2100 forassembling an electronic device having a case bottom piece, a case topfront piece, and a case top back piece, commensurate with an embodimentof the present principles;

FIG. 21 is a flow diagram showing an exemplary method 2200 fordisassembling an electronic device having a case bottom piece, a casetop front piece, and a case top back piece, commensurate with anembodiment of the present principles;

FIGS. 22-25 show perspective views of circuit board assemblyconfiguration 500 having wire securing slots 540 on one of the printedcircuit boards to which the current principles are applied;

FIG. 26 is a perspective view of the circuit board assemblyconfiguration 500 highlighting the connector 503 to which the currentprinciples are applied;

FIGS. 27-28 are interior perspective views of the vertically orientedelectronic device 200 showing the circuit board assembly configuration500 to which the current principles are applied;

FIG. 29 is a flow diagram showing an exemplary method 4800 forassembling an electronic device having a case bottom piece, a case topfront piece, and a case top back piece having printed circuit boardstaging slots 230, and a printed circuit board having wire securingslots 530, to which the current principles are applied;

FIG. 30 shows a rear perspective view of the set top box without thecase, in which a plurality of antennas 602 are distributed over thecircuit boards 501 and 502;

FIG. 31 shows various perspective interior views of the rear wall 206with different components thereon to which the current principles areapplied;

FIG. 32 shows a perspective view of a single unitary antenna bracket 601that supports the plurality of antennas 602 within the electronic deviceaccording to the current principles;

FIG. 33 shows a rear perspective view of the antenna bracket 601 inrelation to the circuit board 501 according to the current principles;

FIG. 34 shows various perspective views of the antenna bracket 601 andthe pocket 605 therein which support the antennas 602 according to thecurrent principles;

FIG. 35 shows a perspective view of the antenna bracket 601 and theantenna wires 604 routed to one bracket wall 603 according to thecurrent principles;

FIG. 36 shows a perspective view of the antenna bracket 601 and theantenna wire 604 routed to one bracket wall 603 and toward the firstprinted circuit board 501 on the rear wall 206 of the electronic deviceaccording to the current principles;

FIG. 37 shows a rear perspective view of the antenna bracket 601 and theantenna wires 604 routed to one bracket wall 603 and down to the firstprinted circuit board 501 according to the current principles;

FIG. 38 shows two perspective views of the rear wall 206 having slots230 thereon that facilitate easy installment of the antenna wires 604 tothe connectors 606 on the first printed circuit board 501;

FIG. 39 shows a perspective view of the rear wall 206 in which theantenna wires 604 are connected to the connectors 606 on the firstprinted circuit board 501 and in which the first printed circuit boardis staged in the staging slots 230; and

FIG. 40 shows a perspective view of the rear wall 206 in which the firstprinted circuit board attached to the rear wall following the connectingof the antenna wires 604 and the removal of the first printed circuitboard 501 from the staging slots 230; and

FIG. 41 shows two perspective views of the first printed circuit board501 having the wire securing slots 540 thereon.

DESCRIPTION OF EMBODIMENTS

FIG. 1 shows a perspective view of a vertically oriented electronicdevice 200 that houses an antenna bracket 601 and antennas 602. Thedevice can include a top 210, a front wall 208, a rear wall 206, sidewalls 204, and a base 205.

FIG. 2 shows the three principal pieces of the vertically orientedelectronic device 200. The three pieces are the case bottom piece 213,the case top front piece 211, and the case top back piece 212. The casetop front piece 211 and the case top back piece 212 are upper parts ofthe device 200.

FIG. 3 is a perspective view of a retention clip 214 which can beoptionally composed of metal and is utilized to engage and secure thecase bottom piece 213 to the case top front piece 211 and/or the casetop back piece 212. The retention clip 214 is positioned toward thebottom of the electronic device and is a key part of the lockingmechanism applied on the electronic device. By having the retention clip214 at the bottom, the antenna bracket 601 and the antennas 602 can bepositioned at the other end of the electronic device; hence, the antennabracket 601 (shown in FIG. 36 at the top end of the rear wall 206) andthe antennas 602 do not interfere with locking and/or unlocking of theelectronic device. Additionally, the use of the retention clip 214 inconcert with other features to be described permits easy access to theantenna bracket 601 and the antennas 602 when needed. The retention clip214 can be part of a screwless locking mechanism positioned adjacent tothe base 205 of the electronic device and can be remote from theantennas in the antenna bracket 601, especially when they are positionedadjacent to the top 210.

FIG. 4 shows how the case top front piece 211 is slid back onto the casetop back piece 212 of the electronic device 200, and then up intoretaining elements in order to lock the two pieces together such thatinternal electronic components can be housed therein when the assemblyis finalized.

FIGS. 5-7 show the specific engagement mechanism 215, 216, 217 to whichthe current principles are applied. A protruding ledge 216 extendsinwardly from the interior surface of one of the vertical walls of oneof the pieces. The protruding ledge 216 includes a protrusion 215 thatengages a protrusion receiving opening 217 on the case top front piece211. The protrusion receiving openings 217 are generally horizontalledges that have upstanding peripheral walls to make a slot that canreceive the protrusions 215. The slots can be oversized in the dimensionthat is perpendicular to the interior surfaces of the vertical wallsfrom which the horizontal ledge extends, or the slots can be oversizedalong its long lateral axis. The slot can be narrow along the dimensionparallel to the vertical walls or along the horizontal ledge's shortlateral axis to snuggly fix the protrusions 215. The protruding ledge216, the protrusions 215, and the protrusion receiving openings 217 forma screwless engagement structure 977. The arrangement of the protrudingledges 216 and the protrusions 215 can be spaced from the interior topsurface of the case top 210 to permit the antenna bracket 601 and theantennas 602 to be positioned at a lateral level between the interiortop surface of the case top 210 and the protruding ledges 216 and theprotrusions 215. This permits the antenna bracket 601 and the antennas602 from interfering with the locking and/or unlocking the pieces of theelectronic device. FIGS. 8 and 9 show further perspective views of theretaining elements that are used to engage the case top front piece 211with the case top back piece 212. FIG. 8 shows ribs 218 that arepositioned above the protrusion receiving openings 217 and also extendinwardly from the interior surface of one of the vertical walls of thefront piece 211. The ribs 218 would interfere with the case rearretention element if an assembly start position is attempted that is toolow. FIG. 9 shows that a chamfer 299 guides the case top 210 to anacceptable start location. Rib 218 prevents case front from starting ina position that is too low by preventing excessive case travel which candamage components.

FIG. 10 is a disassembled perspective view of the vertically orientedelectronic device 200 showing the interior of the case top front piece211 and the case top back piece 212 of the electronic device 200 towhich the current principles are applied. The retention protrusions 291,the retention openings 292, and the over travel prevention portions 293are shown in FIG. 10.

FIG. 11 is a bottom perspective view of the vertically orientedelectronic device 200 in which the case bottom piece 213 is notattached.

FIGS. 12-14 are various views of the retention clip 214 to which thecurrent principles are applicable. The retention clip 214 can beoptionally composed of metal. The views show that the case top frontpiece 211 and the case top back piece 212 can be attached to one anotherand can then be attached to the case bottom piece 213 using theretention clips 214. The retention clips 214 are retained by elements onthe case top front piece 211 and the case top back piece 212. The clip214 is generally V-shape and includes an anchor portion 220 which is oneside of the V-shape. The anchor portion 220 has a rectangular planarshape and has an aperture 277 that fits into an anchor base 221 of thecase top front piece 211 and the case top back piece 212. FIG. 14 showshow the aperture 277 of the anchor portion 220 engages a protrusion 221Ain the anchor base 221 such that an inward pointing ledge at the top ofthe anchor portion 220 grasps a top portion of the anchor base 221 and abottom inner wedge grasps the bottom portion of the anchor base 221 tosecure the retention clip 214. This permits a locking portion 219 of theclip 214, which is the other side of the V-shape, to engage withelements of the case bottom piece 213 to close or assemble theelectronic device 200. In particular, referring to FIGS. 15-16, the topof the locking portion 219 can have a horizontal ledge that extendsinwardly to contact a bottom surface of a clip engaging element 222. Thelocking portion 219 can further have an upward extension at the edge ofthe horizontal ledge to engage an edge of the bottom surface of the clipengaging element 222. As shown in 17, the outward spring force of theclip 214 causes the locking portion to move outward to engage theelement 222. Although a V-shape is shown, a U-shape could be employed aswell and both sides of the V or U-shape part can have different heights.The retention clip 214 and the engaging elements 222 can be part of ascrewless locking mechanism positioned adjacent to the base 205 of theelectronic device and can be remote from the antennas in the antennabracket 601 which can be positioned adjacent to the top 210 of theelectronic device.

FIG. 15 is a perspective view of the case bottom piece 213, which showsthe base 205 and the clip engaging elements 222 that extend verticallyupward from the bottom piece 213 to which the current principles areapplied. The clip engaging elements 222 are designed to engage thelocking portion 219 of the clips 214 on the case top front piece 211 andthe case top back piece 212. A screwless clip and spring mechanism 288is formed from the clips 214 and the clip engaging elements 222.

FIGS. 16 and 17 are perspective views showing how the case bottom piece213 engages the case top front piece 211 and the case top back piece 212to which the current principles are applied. Release finger 301 pushesthe locking portion 219 inward to disengage the locking portion 219 asit enters an aperture 223.

FIG. 18 is a bottom perspective view of the vertically orientedelectronic device 200 to which the current principles are applicable.The reason is that the apertures 223 for the unlocking are remote fromthe antenna bracket 601 and the antennas 602.

FIG. 19 is a view of a release fixture 300 to which the currentprinciples are applied. FIGS. 16-19 show the release aperture 223 inbase 205. A release finger 301 on a base of a release fixture 300 ispermitted to enter the release aperture 223 to push the locking portion219 inward toward the anchor portion 220, thereby removing the topportion of the locking portion 219 from the engaging element 222. Thiscan be understood also with reference to FIG. 18 in which the releasefinger 301 (not shown in FIG. 18) will contact the outer edge of thelocking portion 219 and move the locking portion 219 away from theengaging element 222.

FIG. 20 is a flow diagram showing an exemplary method 2100 forassembling an electronic device having a case bottom piece, a case topfront piece, a case top back piece, an antenna bracket and antennasmounted therein. Here, at step 2105, the antenna bracket 601 is mountedonto an interior vertical wall of the case top front piece or case topback piece or mounted to a component that is mounted to the interiorvertical wall of the case top front piece or case top back piece. Atstep 2110, the case top front piece 211 is attached to the case top backpiece 212 to form a top structure 210 using a screwless engagementstructure 977. At step 2120, the top structure 210 is attached to thecase bottom piece 213 using a plurality of screwless clip and springmechanisms 288. The case top back piece 212 includes printed circuitboard staging slots 230 which are described in greater below.

The issue that arise with the antennas within the method above is thatthe antennas must be electronically connected to the antenna connectorson one or more printed circuits and it is difficult to make theplurality of connections. This difficulty can arise with otherconnections to the one or more printed circuits, because it is difficultto make certain connections when the circuit boards in already attachedto casing walls and because it is difficult to hold the circuit boardsstill with one hand and make a plurality of connections with the other.

FIG. 21 is a flow diagram showing an exemplary method 2200 fordisassembling an electronic device having a case bottom piece, a casetop front piece, and a case top back piece having the antenna bracket601 mounted therein. The method 2200 is applied to an assembledcondition, wherein the case top front piece is attached to the case topback piece 212 to form a top structure 210 using a screwless engagementstructure 977, and the top structure is attached to the case bottompiece using a plurality of screwless clip and spring mechanisms 288. Atstep 2210, a release fixture 300 is moved vertically upward to cause therelease fingers 301 to also move vertically upward toward a bottom ofthe electronic device to simultaneously disengage a locking portion 219of each of the plurality of screwless clip and spring mechanisms 288,thereby allowing the case top front piece 211 and the case top backpiece 212 to be removed upward from the case bottom piece 213. At step2220, the case top front piece 211 slides down with respect to the casetop back piece 212 to disengage the screwless engagement structure 977and separate the case top front piece 211 from the case top back piece212 such that electronic components included within the electronicdevice can be accessed.

The electronic device 200 can be a set-top box or the like and can bevertically oriented such that the height of the device is higher thanthe width of the front vertical surface and/or the rear vertical surfaceand/or the lateral depth. The lateral cross section can be aquadrilateral shape in which the front and back are parallel and theside surfaces are not parallel to one another. The device can bedesigned such that the release fixture and release fingers movevertically upward toward the bottom of the device to simultaneouslydisengage the plurality of the locking portions to allow the case topfront piece 211 and the case top back piece 212 to be remove upward fromthe case bottom piece 213. The case top front piece 211 and the case topback piece 212 can then further be detached from one another by movingthe case top in a motion oppose to that shown in FIG. 5 to attach thetwo pieces (case top front piece 211 and case top back piece 212). Withthe two pieces 211 and 212 attached, the assembly can be reassembled orassembled by aligning the clip engaging elements 222 with the clip 214when the release fixture is removed or not present.

As noted above, the electronic device 200 can be a quadrilateralgenerally in which the front and back are parallel and the side surfacesare not parallel to one another. However, the general quadrilateralshape can include some additional vertical connecting surfaces to makeat least two additional minor surfaces (i.e. substantially smallervertical surfaces) 280 between the rear wall 206 and side walls 204 (asshown in FIG. 4).

Further disclosed is a method of making a printed circuit board toprinted circuit board electrical connection or configuration 500 when asecond printed circuit board 502 is positioned at a right angle to theprimary printed circuit board 501. This can include the second PCB beingconnected behind the primary PCB on the component side 504 and thesecond printed circuit board being positioned on a non-component orbottom side 505 of the primary PCB. The connection for the two PCBs isthrough connector 503.

FIGS. 22-25 show perspective views of circuit board assemblyconfiguration 500 which can be employed in the vertically orientedelectronic device 200 to which the current principles are applied. Theseviews show wire securing slots 540 on the primary printed circuit board501 along its upper edge. These slots 540 can be associated withconnectors 606 which can be antenna connectors for antenna wires 604.The small plan view cross-section area of the configuration 500 from abottom perspective makes the configuration 500 commensurate with thescrewless casing design of the vertically oriented electronic device200. The reason is the plan view cross-section can effectively be aT-shape that can be positioned by design to avoid the screwless lockingmechanism or vis-versa. Further, by having the antenna bracket 601mounted in the finished product at heights in the device in which mostof the antenna bracket 601 is above the top edge of the verticallyoriented primary printed circuit board 501 makes the arrangement of theinternal components further commensurate with the screwless casingdesign. With such an arrangement, the locking elements of the housingand the associated release fixture and release fingers for disassemblycan be more freely positioned to avoid contacting or interfering withthe printed circuit boards and/or other components. If one of thecircuit boards were to be horizontally positioned, there would be lesspositions and greater constraints on the positioning of the lockingelements of the housing and associated release fixture and releasefingers. The circuit boards would need to be smaller and/or need to bepositioned at higher locations with the device.

Since a component side 504 of PCB 501 can face a rear wall 206 of thehousing of the electronic device, a problem is that access to thecomponents on the component side 504 and access to a secondary PCB 502may need to be made through an undesirable cable. Cables add cost and apoint of potential failure. However, the connector 503 in FIG. 23provides a way for the secondary PCB 502 to be directly attached to theprimary PCB 501 in which the secondary PCB 502 is inserted into theconnector 503. This arrangement reduces cost, improves quality and makesassembly easier, with fewer possibilities for assembly error.

Because the PCB arrangement shown in FIGS. 22 and 23 reduces the numberof cables, it makes room for the use of the plurality antenna cables orwires 604 needed to transmit antenna electrical signal within thedevice. As observed in FIG. 24, if the antenna connectors 606 arepositioned near the top edge of the first printed circuit board 501, itis possible to have the antenna connectors 606 on the component side504. As such, the antenna wires 604 can be short and the overall numberof cables/wires within the device itself can be kept to a minimumnumber.

Also, having the connector 503 being elongated to run along the majoraxis adds stability to the support of second PCB 502 and such aconfiguration of the connector 503 being positioned in a central portionof the primary board 501 allows the second board 502 to fit moreconveniently in the casing in which case top front piece 211 has atapered shape in which the casing narrows to the front wall 208.

As shown in FIG. 25, in an embodiment, a portion of the second printedcircuit board 502 includes an extension 591 of the second printedcircuit board from a plane 592 that substantially abuts a surface of thesecond printed circuit board when the first printed circuit board 501 isconnected to the second printed circuit board by the connector 503.Contacts 588 are arranged on the extension 591.

FIG. 26 is a cross sectional perspective view of a circuit boardassembly configuration 500 highlighting the connector 503 and showingthe contacts 506 that are on the interior cavity 508 of the connector503 to which the current principles are applied. The connector 503 canbe a rectangular structure having peripheral walls 507. The rectangularstructure can have a leading edge 510 that can be a flange that facesthe component side 504 of the PCB 501 and contacts the PCB 501 and aportion of the connector 503 that protrudes through aperture 509 in thefirst PCB 501. The connector 503 can extend back to the panel jack atthe panel jack opening or can be connected to a cable running to thepanel jack. The panel jack can be on the rear wall 206 of the electronicdevice or can be a part of the rear wall. The rear wall 206 can be partof the case top back piece 212 in which some of the lower rectangularfeatures on the piece 212 in FIG. 11 can represent a panel jack.

FIGS. 27-28 show interior perspective views of the vertically orientedelectronic device 200 illustrating the circuit board assemblyconfiguration 500 to which the current principles are applied. Theseviews show that the primary PCB 501 can be screwed, bolted, or securedto the rear case or the case top back piece 212.

The view in FIG. 28 further illustrates that the secondary PCB 502 canhave a heat spreader or heat sink 512 on one of its sides. The heatspreader or heat sink 512 can have a central contact portion 513 thatthermally contacts the PCB 502 or heat generating components thereon.The spreader or sink 512 can have a planar peripheral portion thatpermits heat to be radiated or convected away from the PCB 502.

In an embodiment, the heat spreader or heat sink 512 can be generallyparallel to the PCB 502 and both heat spreader or heat sink 512 and PCB502 can be perpendicular to the PCB 501. The heat spreader or heat sink512 can further provide structural support for the second PCB 502. Here,the heat spreader or heat sink 512 can have a base edge with a verticalledge 588 that connects to the first PCB 501 or the case back 212 tosupport by the heat spreader 512 and in turn the heat spreader 512support the second PCB 502 through contact points 514 (which can bescrews or bolts or the like). The contact points 514 can work inconjunction with connector 503 to support the PCB 502. The contactpoints can run along an edge of the PCB 502 opposite the edge of PCB 502having the base edge (support edge). Other mechanical connectionfeatures 799, such as screws or bolts, can secure the main board 501 tothe electronic device 200.

FIG. 29 shows an exemplary method 4800 for assembling an electronicdevice having a case bottom piece, a case top front piece, and a casetop back piece having printed circuit board (PCB) staging slots 230. Atstep 4801, one can provide an interior vertical wall of a case piece 206having PCB staging slots 230 attached or formed thereon. These stagingslots 230 will be discussed in more detail below and are shown in FIGS.31, 33, 36, 38, and 39. At step 4802, the antenna bracket 601 withantennas 602 can be mounted onto the interior vertical wall or to acomponent thereon. It should be understood that alternatively theantennas 602 can be added to the bracket 601 after the mounting of thebracket. At step 4803, the PCB 501 is provided having wire securingslots 540 and the antenna wires 604 can then be inserted into the wiresecuring slots 540 in which the wire securing slots can be an L-shape tosupport one wire or a T-shape (i.e. made by an L-shape and it mirrorimage combined) to support two wires in which the T-shape is invertedcompared the L and one wire goes to the left side and one wire goes tothe right side of the line segment of the T-shape that is parallel tothe edge of the printed circuit board . The L-shape and T-shape cutoutsare shown in FIG. 31D which is a magnified view of FIG. 31C in the wiresecuring slots region 541, At step 4804, an edge of the printed circuitboard 501 is inserted into the staging slots 230 such that the printedcircuit board (PCB) stands at an angle with respect to the interiorvertical wall, and the antenna wires 604 can be connected to antennaconnectors 606 on the printed circuit board. This is an intermediateprocess step and shown in FIG. 38. These steps 4802 and 4803 can also beused or can alternatively be used to make other connections to theprinted circuit board or printed circuit boards. At step 4804, theprinted circuit board is removed from the staging slots and is attachedto the interior vertical wall. At step 4805, the case piece having theprinted circuit board is attached to other case pieces and the casing isclosed to complete the assembly of the electronic device 200. Thismethod 4800 can include one or multiple printed circuit boards in anelectronic device 200. The mounting of the bracket can include the useof screws, bolts or the like. The method can include connecting thesecond printed circuit board 502 to the first printed circuit board 501in a perpendicular configuration 500 by the connector 503 on the firstprinted circuit board 501, by passing a portion of the second printedcircuit board 502 through a second side of the first printed circuitboard 501 to engage the connector 503 on the first side of the printedcircuit board 501. The method can also include providing a structuralsupport for a heat spreader or heat sink 512 having at least a portionthereof thermally contacting the second printed circuit board 502 or oneor more heat generating components on the second printed circuit board502, by connecting a vertical ledge of the heat spreader or heat sink512 to the first printed circuit board 501 or to the case top back piece212.

Although the staging slots have been beneficial, an embodiment of thecurrent principles includes features as described in FIG. 29, but withno staging slots for the supporting the printed circuit board while theantenna wires are inserted in the wire securing slots. Instead thecircuit board with the wire securing slots can be appropriately stagedby something other than the staging slots such that the wires can beinserted in the wire securing slots.

FIG. 30 shows the feature of the set top box without the case in which aplurality of antennas 602 are distributed over the printed circuitboards 501 and 502 and outside the peripheries of one or both of theorthogonally arranged printed circuit boards 501 and 502. An embodimentcan include only one board and less than 7 antennas. Here, the firstprinted circuit board 501 with a board heat spreader and heat sink 520(in which “board” refers to the heat sink or spreader being associatedwith the circuit board) is attached to one side of the first printedcircuit board 501 that is opposite the side that connects to the secondprinted circuit board 502. The board heat spreader and heat sink 520 isbetween the first printed circuit board 501 and the rear wall 206 of thecase top back piece 212 of the casing of the electronic device. Theantennas 602 are connected to one of the circuit boards and, in thisembodiment, are all attached to the first printed circuit board 501. Theantennas 602 can be connected to the antenna connector 606 on the firstprinted circuit board 501 by way of the antenna wires 604. The antennascan be WIFI antennas and can be vertically oriented in the verticallyoriented set top box as shown and positioned adjacent to the top 210between the outer top peripheral edges of the printed circuit boards andthe top 210 of the set top box. The antennas positioned along the rearwall 206 can be parallel to the rear wall 206 and laterally positionedto be between a vertical plane extending from the plane of the firstprinted circuit board 501 and the rear wall 206. The antennas 602 can belaminated antenna printed circuit boards.

FIG. 31A shows the rear wall 206 of the case top back piece 212 that isomitted in FIG. 30. FIG. 31B shows the board heat spreader and/or heatsink 520 positioned adjacent to the rear wall, and FIG. 31C shows thefirst printed circuit board 501 which is connected to the board heatspreader and/or heat sink 520 thereover. These figures also show thestaging slots 230 positioned on the interior wall of the rear wall 206.

Inspection of FIG. 30 shows that interior volume of vertically orientedelectronic devices can be quite crowded with a complex arrangement ofcomponents that comprise circuit boards, the components on the circuitboards, and the components to which the circuit board components arephysically or electronically connected. This crowdedness and complexityis further enhanced when a plurality of antennas is need, because theconventional arrangement of the antennas involves having its ownindependent support. This, in turn, adds to the number of interiorcomponents that must be individually staged, isolated from othercomponents and installed. Further, in these vertically orientedelectronic devices, it turns out that there are spatial constraints andinefficiencies with the individual supports. In other words, the needfor rapid assembly in high volume factories makes it difficult tomanufacture such devices in which the antennas are individuallysupported with their own supports.

In view of the above mentioned issues with individual supports and theneed to shield and connect antennas, a single unitary antenna bracket601 provided and shown in FIG. 32 for holding the plurality of antennas602 and the staging slots 230 provided and shown in FIG. 31 are helpful.The perspective view of FIG. 32 shows the antenna bracket 601 that holdsmultiple antennas and antenna wires 604. The antenna bracket includesmultiple bracket walls or sides 603 to form a polygon structure andantenna pockets 605 supported on at least two bracket walls, wherein theantennas fit within the pockets and the pockets prevent electrostaticdischarge to and/or from the antennas. The antenna bracket 601 can haverounded corners and the sides 603, and the corners can follow orgenerally follow the interior contour of the vertical walls of thecasing. FIG. 33 show a rear perspective view of the antenna bracket 601in relation to the printed circuit board 501 and in relation to thestaging slot 230. FIG. 36 further shows the wire securing slots region541 in which the plurality of the wire securing slots 540 can bedistributed along an end of the printed circuit board 501.

FIG. 34 shows various perspective views of the antenna bracket 601 andhow the antennas 602 slide into the pockets 605. In particular, thecorner region 610 of the bracket 601 highlighted in FIG. 34A is enlargedin FIGS. 34B and 34C to show how the antenna 602 can be inserted intoand supported by the pockets 605. The pockets 605 have a hollowstructure with two broad walls parallel to the broad surfaces of theantenna and two openings. The pockets can further include two narrowopposing end walls that bridge the two broad walls. One opening can beat the top for the antenna to slide into and another opening at thebottom for the antenna wire 604 to extend through to connect preferablyto one of the printed circuit boards.

FIG. 35 shows a perspective view of the antenna bracket 601 and how theantenna wires 604 can be routed to one bracket wall 603. This view alongwith the view in FIG. 30 shows that the antenna wires 604 can be routedfrom end of the antenna pockets 605 along the bracket walls 603 towardone of the bracket walls 603 and downward toward the antenna connector606. Also, FIG. 35 and FIG. 34 show that the antenna bracket 601 canhave mounting apertures 611 on at least one of its walls 603 to securethe bracket 601 to a wall of the housing of the electronic device or toa printed circuit board.

FIG. 36 shows a perspective view of the antenna bracket 601 and how theantenna wire 604 can be routed to one bracket wall 603 and down to thefirst printed circuit board 501 between the first printed circuit board501 and the rear wall 206. The wires 604 can connect to connectors 606at the edge of the first printed circuit board 501. This view shows thatthe bracket 601 and the printed circuit board can both be attached tothe same wall 206 of the housing of the electronic device. FIG. 36 showsthat the antenna bracket 601 can be positioned above the staging slots230 and the printed circuit board 501 can be positioned below thestaging slot 230 in the final configuration, after the antenna wires 604are attached and the circuit board 501 is removed from the stagingslots. FIG. 36 further shows the wire securing slots region 541 in whichthe plurality of the wire securing slots 540 can be distributed along anend of the printed circuit board 501.

FIG. 37 shows a rear perspective view of the antenna bracket 601 and howthe antenna wire 604 can be routed to one bracket wall 603 and down tothe first printed circuit board 501 and connect to antenna connector 606at the edge of the first printed circuit board 501. This view shows thatthe bottom edge of the bracket wall 603 to which each of the wires 604are routed can be separated from the top edge of the printed circuitboard 501 to which the wires 604 are routed.

Although quite helpful, the implementation of the antenna bracket 601shown in FIG. 37 has problems. It is difficult to attach the wires 604when the first printed circuit board 501 is already attached to rearwall 206, because there are spatial constraints that do not allow foreasy access to the side of the printed circuit board 501 that faces therear wall 206. It is also difficult to attach the wires 604 to theconnectors when the bracket 601 is already attached to the wall 206 andthe circuit board is not yet attached, because one needs to hold thecircuit board 501 up with one hand and then try to connect each wire 604individually. This is tedious and time consuming and requires greatcare, because the wires 604 are kept at short lengths to ensure they fitin the housing, to ensure they do not interfere or entangle with othercomponents, and to save on material costs. Attaching the wires to thecircuit board before both the bracket and circuit board are connected tothe rear wall 206 is also problematic, because some wires tend todisconnect due the difficulty in handling the bracket and board togetherwhen they are separate components that are intentionally not rigidlybound together. The method 4800 in FIG. 29 addresses this problem withthe introduction of the staging slots 230.

As such, the solution to ensure easy connections of the wires 604 to theconnectors 606 on the first printed circuit board 501 can be betterunderstood with reference to FIGS. 38A and 38B and the method describedin FIG. 29. FIG. 38A is a magnified view of section 570 of theintermediate assembly shown in FIG. 38B. In the view shown in FIG. 38A,the antenna wires 604 are not yet inserted into the wire securing slots540. After the board heat sink is attached to the back wall 206 as shownin FIG. 31B, the circuit board 501 can be placed in staging slots 230.As such, the rear wall 206 of the casing of the electronic deviceincludes staging slots 230 that are adapted to support the circuit boardin a vertical or upstanding position with respect to the rear wall 206,which is oriented horizontally to permit access and viewing of theunderside of the printed circuit board. Once the antenna wires 604 areattached to the connectors 606, the circuit board 501 is removed fromthe staging slots 230 and oriented parallel to the rear wall for theremaining steps and final assembly which is shown in FIG. 310 that omitsthe bracket. There can be two staging slots 230 which can have C-shapes,U-shaped or V-shaped profiles in which the open ends face one another.These profiles of the staging slots can extend perpendicularly inwardfrom the rear wall 206 to have a sufficient depth to be able to supportthe printed circuit board which can be parallel to the bracket 601 atpoint in this temporary state.

FIG. 39 shows the antenna wires 604 attached to the connectors 606. Atthis point, the circuit board 501 can be removed from the staging slots230 and oriented parallel to the rear wall 206 for the remaining stepsand final assembly.

FIG. 40 shows the circuit board 501 after being removed from the stagingslots 230 and oriented parallel to the rear wall for the remaining stepand final assembly.

FIG. 41A shows a perspective view of the non-component/bottom side 505of the first printed circuit board 501 having the wire securing slots540 thereon.

FIG. 41B shows a perspective view of the component side 504 of printedcircuit board 501 having the wire securing slots 540 thereon.

The implementation of the wire securing slots 540 shown in FIG. 41 hasbeen proven to be quite helpful in the assembling of the verticallyoriented electronic device 200 having the antenna brackets 601. The wiresecuring slots 540 removes or substantially reduces the strain on theantenna wires that invariably occurs and causes some coaxial connectorsof the antenna wires 604 to unplug after the plugging step.

This might occur in the various methods for assembling the device. Forexample, in the case with the following order of steps: placing the rearwall 206 of the casing on a bench; adding or installing the heatspreader or heat sink 512 to the rear wall; adding or installing theantenna bracket 601 to the rear wall 206; placing the printed circuitboard 501 on the bench; plugging the antenna wires 604 onto coaxialantenna connectors 606; adding the printed circuit board 501 withantennas 602 to the rear wall; routing the antenna wires 604 andantennas 602 to proper locations in the bracket.

With the implementation of the wire securing slots 540, the step ofplugging the antenna wires can include sliding and/or securing theantenna wires 604 into the wire securing slots such that there is nostrain between the antennas wire as it comes out from the wire securingslot 540 and extends to the antenna connector 606 on the printed circuitboard.

In sum, FIG. 41 shows a solution to the antenna wire strain problem. Thesolution is the additional step or feature of adding wire securing slots540 on the printed circuit board. As illustrated in the figures, therecan be two types of wire securing slots 540: a single hook and a doublehook cutout that curve from an edge of the printed circuit board 501.The hooks or slots of the wire securing slots 540 can have a J-shape oran L-shape cutout in the plane of the applicable printed circuit board.The advantage of the double hook is that one double hook takes up lessroom than 2 single hooks to accommodate two wires. If the L-shape isused and a single cutout is desired to accommodate two wires, a T-shapecan be employed. The orientation of the T-shape would be invertedcompared to the L-shape or the J-shape. The feature of the wire securingslots 540 can be incorporated with any of the assembly process. The keyis that the J-space or L-shape permits the edge of the board 501 to holdthe wire while the end of the wire 604 is connected. The J-space orL-shape grasps or holds the wire securely to permit the manipulation ofthe dangling or free portion of the antenna wire 604. The J-shape caninclude a flat bottom portion at the bottom of the J and a short curledportion (upward portion). The opening of the slot width must be largeenough to accommodate the width of the wire; however, the wire securingslot 540 can taper down so the wire can be gripped tighter as the wireis advanced in the slot. The wire 602 can be secured in in the wiresecuring slots 540 by pushing the wire into the slot in a direction inthe plane of the board and parallel to the linear part of the J-shapenear the opening. The downward portion of the J-shape or L-shape can beperpendicular to the edge of the printed circuit board. The antenna wire602 can remain in the wire securing slot 540 after the connection to theconnector 606. The wire 602 can rest at the bottom of the J-shape orL-shape or can rest at the short curled up portion of the J-shape if theJ-shape is employed. Although a J-shape and an L-shape have beendisclosed here, other effective shapes are also possible that caninclude some longer entrance portion (downward portion), some bottomportion or cusp portion and some upward portion back toward the edge ofthe board. For example, different versions of a check design (✓) can beutilized, which can include one or both strokes (i.e. upward anddownward) at an acute angle with the edge of the printed circuit boardor one stroke perpendicular to the edge of the printed circuit board.

It should be noted that all examples and conditional language recitedherein are intended for pedagogical purposes to aid the reader inunderstanding the present principles and the concepts contributed by theinventors to furthering the art, and are to be construed as beingwithout limitation to such specifically recited examples and conditions.

Moreover, all statements herein reciting principles, aspects, andembodiments of the present principles, as well as specific examplesthereof, are intended to encompass both structural and functionalequivalents thereof. Additionally, it is intended that such equivalentsinclude both currently known equivalents as well as equivalentsdeveloped in the future, i.e., any elements developed that perform thesame function, regardless of structure.

Although the illustrative embodiments have been described herein withreference to the accompanying drawings, it is to be understood that thepresent principles are not limited to those precise embodiments, andthat various changes and modifications may be effected therein by one ofordinary skill in the pertinent art without departing from the scope ofthe present principles. All such changes and modifications are intendedto be included within the scope of the present principles. For example,although the embodiments generally refer to the components with avertically oriented electronic device in which the vertical height ofthe device can be greater than the horizontal length of each of the sidewalls, the principles are intended to be useful and are intended toinclude horizontally oriented electronic device.

Additionally, although the sides of the vertically oriented electronicdevice as well as other components are characterized as being “vertical”or “vertically oriented,” it should be understood that these expressionare intended to include surfaces which may have some curvature or somesmall deviations from being completely vertical (e.g. +/−10° fromvertical can be considered vertical).

Also, it is intended that the expressions “rear” and “front,” theexpressions “top” and “bottom,” and the expressions “vertical” and“horizontal,” as well as other complementary terms are intended to beconstrued from the perspective of the observer of the figures; and assuch, these expression can be interchanged depending upon the directionthat the observer observes the device.

1. An electronic device comprising: a printed circuit board having wiresecuring slots along an edge of the printed circuit board and electricalconnectors on a side of the printed circuit board adjacent to the edge;and electronic components having wires extending therefrom, the wireseach passing through and being secured in a respective one of the wiresecuring slots and connected to one of the electrical connectors.
 2. Theelectronic device of claim 1, wherein the electronic components areantennas and the electrical connectors are each positioned laterallywith respect to the wire securing slots in a direction parallel to theedge of the printed circuit board.
 3. The electronic device of claim 1,wherein the electronic device is a set top box or gateway device, thewire securing slots are substantially a J-shape, substantially a checkdesign (✓), substantially an L-shape, or substantially a T-shape, andthe electronic components are antennas.
 4. The electronic device ofclaim 1, wherein: the electronic components are antennas; the electronicdevice is a set top box or gateway device having a casing that is avertically oriented structure in which the height of the casing isgreater than horizontal widths of each of its sides and all horizontaldepths of the casing; and the electronic device comprises an antennabracket positioned above the printed circuit board and supporting theantennas.
 5. The electronic device of claim 4, wherein: the printedcircuit board is positioned vertically and the edge is an upper edge ofthe printed circuit board; and the antenna bracket is a polygonalstructure having at least two sides in which some of the antennas are onat least two of the sides.
 6. The electronic device of claim 5, wherein:the printed circuit board secured to a rear wall of the casing andparallel to the rear wall; the antenna bracket is secured to a rear wallof the casing; and the wires of the antennas are routed to one of thesides of the antenna bracket and down to the wire securing slots.
 7. Theelectronic device of claim 6, wherein the electrical connectors are eachpositioned laterally with respect to the wire securing slots in adirection parallel to the edge of the printed circuit board.
 8. Theelectronic device of claim 1, wherein: the electronic components areantennas; the electronic device is a set top box or gateway device; andthe electronic device comprises an antenna bracket positioned above theprinted circuit board and supporting the antennas.
 9. The electronicdevice of claim 8, wherein: the printed circuit board is positionedvertically and the edge is an upper edge; and the antenna bracket is apolygonal structure having at least two sides in which some of theantennas are on at least two of the sides.
 10. The electronic device ofclaim 9, wherein: the printed circuit board secured to a rear wall ofthe electronic device and parallel to the rear wall; the antenna bracketis secured to a rear wall of the casing; the wires of the antennas arerouted to one of the sides of the antenna bracket and down to the wiresecuring slots; and the wire securing slots are substantially a J-shape,substantially a check design (✓) shape, substantially an L-shape, orsubstantially a T-shape.
 11. The electronic device of claim 10, wherein:the electronic device has a casing that is a vertically orientedstructure; and the rear wall has at least one staging slot, the stagingslots are configured to temporarily support the printed circuit boardduring assembly of the electronic device.
 12. A method of constructing aset top box or gateway device having a casing comprising: providing aprinted circuit board having wire securing slots along an edge of theprinted circuit board and electrical connectors on a first side of theprinted circuit board adjacent to the edge; routing wires of electroniccomponents into the wire securing slots such that the wires enterthrough a second side of the printed circuit board and exit the firstside; connecting the wires to the electrical connectors; attaching theprinted circuit board to a wall of the casing; and closing the casing.13. The method of claim 12 further comprising forming wire securingslots by cutting or punching substantially a J-shape, substantially acheck design (✓) shape, substantially an L-shape, or substantially aT-shape cutout along the edge of the printed circuit board.
 14. Themethod of claim 12 further comprising: providing an antenna brackethaving a polygonal structure having at least two sides, at least two ofthe sides having pockets for supporting at least one of the electroniccomponents, wherein the electronic components are antennas; routing thewires of the antennas into the pockets of the antenna bracket; andmounting the antenna bracket to the wall of the casing.
 15. The methodof claim 12, wherein the casing is a vertically oriented structure andthe printed circuit board is oriented vertically and parallel to thewall.
 16. The method of claim 14, wherein the edge of the printedcircuit board having the wire securing slots is an upper edge of theprinted circuit board and the edge is at a lower lateral position thanthe antenna bracket upon the closing of the casing.
 17. The method ofclaim 12 further comprising: holding the printed circuit board instaging slots on the wall of the casing during the connecting of thewires such that the printed circuit board is at an angle with respect tothe wall; and removing the printed circuit board from the staging slotson the wall for the mounting of the printed circuit board.
 18. A methodfor constructing a sub-assembly for incorporating into a plurality ofdifferent set top boxes and gateway devices, comprising: forming aplurality of slots along an edge of a printed circuit board; arranging aplurality of electrical connectors on a side of said printed circuitboard adjacent to said edge; providing a plurality of antennas withrespective lead wires; securing said respective lead wires in respectiveones of said slots; and, operatively connecting said lead wires torespective ones of said electrical connectors.
 19. The method of claim18, further comprising: supporting said antennas from a position abovesaid printed circuit board.
 20. The method of claim 19, furthercomprising: positioning said electrical connectors laterally withrespect to said slots, in a direction parallel to said edge of saidprinted circuit board.